Technologies Developed & Ready for Commercialization

Circot Lap Preparation Machine for Micro Spinning

Circot Lap Preparation Machine for Micro Spinning

Description and salient Technical features

Traditionally fibres are opened by ‘Pinjari’ by using catgut and laps are made manually. But this process is laborious, time consuming and accuracy is not maintained as per requirement. CIRCOT lap preparation machine consists of moving apron, flutted feed roller, mote knife, likerin cylinder and laping cylinder. Prime drive is operated by a one hp and single phase electric motor and

total system is monitored by PLC system. Required quantity (60 – 100g) of fibres are placed on the moving apron end and gradually passing through the flutted roller and lickerin where proper opening and cleaning of fibres take place. Then these cleaned and opened fibres are transferred to another pair of cylinder for formation of laps. The laps are then fed to carding and ring frame for making yarn.

Performance Results

Lap weight60 – 100 g
Output5 laps/h

Cost: 2.5 Lakh

How the new technology will impact the income of the farmers / end users:

Drugery of operation is reduced. More number of samples can be produced with less labour. Sample analysis through micro spinning will become easier and economical.

Eco-friendly Packaging Material from Cotton

Eco-friendly Packaging Material from Cotton

Description and salient Technical features

The kraft paper made from cotton stalks can be conveniently used for the preparation of good quality 3-ply and 5-ply corrugated boards. Corrugated boxes of various dimensions can be prepared using these boards. These boxes conform to BIS specifications. Suitability of these boxes was also ascertained by conducting actual packaging, transportation and storage trials with fruits like oranges and mangoes.

The performance of these boxes was found to be on par with that of wooden boxes as well as CFB boxes made from commercial kraft paper. These boxes could be effectively used for packaging, transportation and storage of various horticultural produce. The 5 kg and 10 kg capacity boxes (3 ply) were most ideal for packaging and transportation of mangoes. Ripening and physical condition of fruits were better and uniform in cotton stalk CFB boxes as compared to nailed wooden boxes. For packaging, transportation and cold storage of oranges, two piece telescopic boxes of size 50 x 30 x 30 cm (5 ply + 3 ply) is recommended.

Cost: 

Production cost of 2000 corrugated boxes (size : 265 x 180 x 105 mm) from 1 tonne of craft paper is Rs 20,758 approx.


How the new technology will impact the income of the farmers / end users:

Additional benefits can be found in the expected reduced use of wood as a basis for paper manufacturing and packaging, which has strong environmental benefits, and in the possibility to create new rural based small board manufacturing units.
Main beneficiaries will thus be the cotton farmers who will generate additional income from the sale of cotton stalks.

Social/environmental/other benefits

It will partly solve the raw material problem of the paper industry and fetch additional income to the farmer community. Losses during transportation of fruits will be minimized.

Nano Cellulose Preparation by Homogenization Process

Nano Cellulose Preparation by Homogenization Process

Description and salient Technical features

A process for preparation of nanocellulose from microcrystalline cellulose (MCC) by homogenization process is established. The MCC is prepared from the cotton fibres / cotton linters by traditional hydrochloric acid hydrolysis process and treated with zinc chloride for 2 hours for swelling. After swelling, the MCC was completely rinsed in water and subjected to homogenization process up to 40,000 psi pressure.

The size of nanocellulose was analyzed by scanning electron microscopy. The average length and thickness of nanocellulose are less than 500 and 50 nm, respectively as analyzed by scanning electron microscopy (SEM).

Performance Results

The untreated MCC required ten passes for complete conversion to nanocellulose while zinc chloride pre-treated MCC required only five passes for complete conversion. So, there is 50% reduction in energy consumption. The yield of nanocellulose is more than 95%.

Cost: Rs.30 Lakh


How the new technology will impact the income of the farmers / end users:

This process will add value to the cotton wastes coming out of textile mills and non-spinnable cotton fibres.

Multi-sheath Feeder to Raspador Fibre Extractor

Multi-sheath Feeder to Raspador Fibre Extractor

Description and salient Technical features

Various types of fibre extractors have been in use for separating fine fibres from raw plant parts. Raspador Fibre Extractor is generally employed to extract fibres from soft pithy plant materials like banana pseudo stem, sisal, hemp, etc. This extractor has a large rotating cylinder called scutching drum with a number of blades over it.

The sheaths are fed between a stationary-roller and the rotating cylinder. During the extraction, pithy matter is separated from fibrous matter by scutching action. Conventionally, for example, a single sheath of banana pseudo stem cut to about 1 metre length is fed to the Raspador Extractor one by one makingthe yield of extractor low. The newly designed feeder attachment can feed about 3-6 sheaths at a time to the extractor with considerable ease. Feeding multiple sheaths simultaneously not only increases the productivity but also reduces cost of production by way of reduced power requirements. This feeder can also be used for extracting other bast and leaf fibres like pineapple, sisal, etc.

Performance Results

Multi-sheath feeder helps to increase fibre production up to 1.5 to 2 times without additional energy consumptions or manpower requirements.

Cost: Rs.25,000 (Approx)

How the new technology will impact the income of the farmers / end users:

The fibres extracted will be used for spinning yarn at the village level or can be marketed for making other value added products. Most of the income thus generated will add to the existing income of the farming families.

Social/environmental/other benefits:

This innovation will help peasants to augment their income and hence will enhance their living standard.

Status of commercialization/ IPO rights etc.

Ready for commercialization

An Attachment to Medlari Charkha

An Attachment to Medlari Charkha

Description and salient Technical features

In the villages in Karnataka Medlari Charkha has been used to spin wool fibres that are available from the sheep and are generally coarse. Medlari Charkha spinning unit is a foot operated self-winding spinning wheel with a bobbin to collect the spun yarn. The count (fineness) of yarn produced depends on the rate at which fibres are fed and is usually around 800-1000 tex.

This traditional form of medlari charkha is not suitable for spinning long length coarse fibres like jute, ramie, banana etc. Due to difficulty in feedingfibres continuously to the spinning unit, fibres which are fed into rotor get twisted. This twisting extends up to the feeding point which is usually fingers of the operator. In the case of fibres like banana, jute, etc., it becomes impossible to feed them with fingers such that portion towards the rotor gets twisted while the portion away from the rotor is still untwisted. In view of this difficulty an attachment is fabricated which helps in feeding fibres and at the same time keeping twisted and non-twisted portions separate. This device is pedal driven.

Performance Results

Capacity : 1 to 1.5 kg of banana fibre yarns

Cost: Rs.6000

How the new technology will impact the income of the farmers / end users:

The yarn produced from the charkha can be used for producing other value added products at the village level which will add to the existing income of the farming families.

Social/environmental/other benefits:

This innovation helps peasants to augment their income.

Status of commercialization/ IPO rights etc.

Ready for commercialization

Rubber Dam for Watershed

Rubber Dam for Watershed

Description and salient Technical features

Flexible rubber dams are a special type of geosystem, which are made up of long tubular-shaped textile composite secured to a channel bed consisting of four parts such as: A rubberized fabric dam body, A concrete foundation, A control room housing (inflation & deflation mechanisms) & An inlet/ outlet piping system.

Advantages of rubber dam are short construction period, easy maintenance and repair, long span and adaptable to different slopes, low project life cycle cost, earthquake resistant.

Performance Results

More durable, stores more water for maximum period of one year and uniform regulation of water flow compared to traditional dams.

Cost:

Total cost of the rubber composite including installation is around Rs.36,900 for five square metres (7380/ m2). Cost of base concrete structure is extra

How the new technology will impact the income of the farmers / end users:

Water will be available for maximum period so that the farmers will go for more number of crops and productivity of each crop will be increased due to assured water availability and farmers are benefitted monetarily.

Social/environmental/other benefits:

As productivity of crop increases farmers will get more returns. Ground water will be recharged. Both soil and water will be conserved.

Status of commercialization/ IPO rights etc.

Ready for commercialization

Defibring Machine for Green Coconut Husk

Defibring Machine for Green Coconut Husk

Description and salient Technical features

A novel prototype has been developed for extraction of fibres from green coconut husk. It works on the principle of fibre-combing. The green coconut husks are fed to a puncher and crusher system and further carried to combing cylinder via a conveyor belt. Combing bars have optimum teeth fitted over a revolving cylinder which rotates at 700 rpm.

Technical Specifications:

Speed of cylinder:700 rpm
Power:3.73kW (3 phase)

Performance Results

Capacity: 60-70 husks/ h

Cost: Rs.2 Lakh

How the new technology will impact the income of the farmers / end users:

Energy efficiency defibring system reduces the loss of coir fibres, improves the cleaning efficiency and productivity of fibres.

Social/environmental/other benefits:

Offshore retting process will be eliminated thereby conservation of water bodies.

Status of commercialization/ IPO rights etc.

Ready for commercialization

CIRCOT Minicard for Sliver Production

CIRCOT Minicard for Sliver Production

Description and salient Technical features

In this machine individualisation and cleaning of fibres are achieved by feeding cotton uniformly to the cylinder and combing it with wire points. Further less neppy and uniform web is converted into sliver by calendar rollers and trumpet. The machine is suitable for making sliver as well as to collect the clean web of cotton for further use.

Technical Specifications:

Overall machine size1.25 x 2.50 x 1.5 m
Cylinder length610 mm
Power1.12 kW
Weight1500 kg

Construction parts: MS angle and sheet, High carbon steel, carding and clothing wire, rubber belt, different types of gears, chain and sprocket, V belt and pulley, wire cleaning roller. Safety guards are provided on both sides of machine. Emergency switch is also provided to ensure safety. One person (semi -skilled) is required to run this machine.

Performance Results

Capacity : 2 kg/h of sliver

Cost: Rs.7 Lakh

How the new technology will impact the income of the farmers / end users:

The roving sliver is outsourced from mills and processing plants to make yarn on Amber and other charkhas. Independency of yarn making at cotton production site i.e. fibre to fabric can be achieved. Additional income avenue for the farmers by production of sliver, web and yarn. The clean web can be used for surgical cotton and equivalent use.

Social/environmental/other benefits:

Development of rural employment and entrepreneurship.

Axial Flow Cotton Pre-Cleaner

Axial Flow Cotton Pre-Cleaner

Description and salient Technical features

It has been mainly developed for on farm cleaning of seed cotton by farmers, traders and for use by cotton ginneries. It removes small trash particles, kawadi, sand and dust. It works on axial flow principle. It consists of cylinder, grid bar, top cover, feeder, and power drive assembly. The machine is made portable by providing wheels. Seed cotton is fed at one end of the spiked cylinder through feeder and it moves axially along the length of the cylinder as it rotates.

The rotational motion of the cylinder draws the cotton inside and agitates it across the grid surfaces. Foreign matter gets dislodged from the cotton by the agitating and scrubbing action of the cylinders and falls through grid bars. The trash gets accumulated in the trash

Salient technical specifications:

Type of cylinderSingle spiked cylinder
Cylinder length:1200 mm
Cylinder diameter:443 mm
Cylinder speed:225 rpm
Power requirement:1.86 kW
Machine size:1.5 x 1.2 x 1.2 m

Improvement over existing system: Presently ginneries use cylinder type pre-cleaners with 4 to 6 cylinders depending on the cleaning efficiency required. These cylinder pre-cleaners work on the principle of feeding the cotton longitudinally i.e. along the length of the cylinder. These pre-cleaners are of high capacity, costlier and require more power and not suitable and affordable to farmers.

Safety: The machine is compact, covered with safety guards and operator friendly.

Performance Results

Output capacity: 650 kg seed cotton/h 
Cleaning Efficiency: 30-40%
Labour requirement: Two unskilled

Cost: Rs.75,000 (Cost of operation: Rs.44/h & Custom hiring rate: Rs.109/h)


How the new technology will impact the income of the farmers / end users:

Axial flow pre-cleaner can be effectively used for on farm cleaning of cotton to realize the better prices for cotton and enhance farm income

Social/environmental/other benefits:

Improvement in quality of cotton and enhanced income of farmers.